Automated truck unloader for unloading/unpacking product from trailers and containers

ABSTRACT

An automatic truck unloader for unloading/unpacking product, such as boxes or cases, from trailers and containers is disclosed. In one embodiment, a mobile base structure provides a support framework for a drive subassembly, conveyance subassembly, an industrial robot, a distance measurement subassembly, and a control subassembly. Under the operation of the control subassembly, an industrial robot having a suction cup-based gripper arm selectively removes boxes from the trailer and places the boxes on a powered transportation path. The control subassembly coordinates the selective articulated movement of the industrial robot and the activation of the drive subassembly based upon the distance measurement subassembly detecting objects, including boxes, within a detection space, and dimensions of the trailer provided to the control subassembly.

PRIORITY STATEMENT & CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/256,888 entitled “Automated Truck Unloader for Unloading/UnpackingProduct from Trailers and Containers,” filed on Sep. 6, 2016, in thename of Tim Criswell, and which issued on Jan. 3, 2017, as U.S. Pat. No.9,533,841; which is a continuation of U.S. patent application Ser. No.14/159,297 entitled “Automated Truck Unloader for Unloading/UnpackingProduct from Trailers and Containers,” filed on Jan. 20, 2014, in thename of Tim Criswell, and which issued on Sep. 6, 2016, as U.S. Pat. No.9,434,558; which claims priority from U.S. Patent Application No.61/754,630, entitled “Automated Truck Unloader for Unloading/UnpackingProduct from Trailers and Containers,” filed on Jan. 20, 2013, in thename of Tim Criswell, all of which are hereby incorporated by referencefor all purposes.

TECHNICAL FIELD OF THE INVENTION

This invention relates, in general, to a machine for handling productsand, more particularly, to a system and method for automated unloadingand unpacking which employ an automatic truck unloader designed tounload and unpack product, such as boxes or cases, from trailers andcontainers.

BACKGROUND OF THE INVENTION

Loading docks and loading bays are commonly found in large commercialand industrial buildings and provide arrival and departure points forlarge shipments brought to or taken away by trucks and vans. By way ofexample, a truck may back into a loading bay such that the bumpers ofthe loading bay contact the bumpers on the trailer and a gap is createdbetween the loading bay and the truck. A dock leveler or dock platebridges the gap between the truck and a warehouse to provide a fixed andsubstantially level surface. Power moving equipment, such as forkliftsor conveyor belts, is then utilized to transport the cargo from thewarehouse to the truck. Human labor is then employed to stack the cargoin the truck. This is particularly true of the unloading of product,such as boxes or cases, from a truck, or freight container, for example.These systems are designed to maximize the amount the cargo unloadedwhile minimizing the use of human labor to both protect and extend thelife of the workforce. Reducing human labor, however, has provendifficult as the configuration and size of the boxes in the truck orfreight container cannot be easily predicted in advance. Therefore, aneed still exists for improved truck unloading systems that furtherreduce the use of human labor when unloading or unpacking product, suchas cases and boxes, from trailers and containers.

SUMMARY OF THE INVENTION

It would be advantageous to achieve a system and method for automatedunloading and unpacking of product, such as cases and boxes, that wouldenable a trailer or container to be fully unloaded using minimal or nohuman labor, thereby minimizing the time to unload the truck and theneed for human capital. It would also be desirable to enable a roboticsolution that would address this problem by unloading and unstackingtrailers and containers with boxes and cases of varying sizes. To betteraddress one or more of these concerns, in one embodiment, an automatictruck unloader for unloading/unpacking product, such as boxes or cases,from trailers and containers is disclosed. A mobile base structureprovides a support framework for a drive subassembly, conveyancesubassembly, an industrial robot, a distance measurement subassemblysuch as a camera utilizing an adaptive depth principle, and a controlsubassembly. Under the operation of the control subassembly, anindustrial robot having a suction cup-based gripper arm selectivelyremoves boxes from the trailer and places the boxes on a poweredtransportation path. The control subassembly coordinates the selectivearticulated movement of the industrial robot and the activation of thedrive subassembly based upon the distance measurement subassemblydetecting objects, including boxes, within a detection space, anddimensions of the trailer provided to the control subassembly. Thesesystems and methodologies utilizing the present automatic truck unloadertherefore maximize the amount the product and cargo unloaded whileminimizing the use of human labor to both protect and extend the life ofthe workforce. These and other aspects of the invention will be apparentfrom and elucidated with reference to the embodiments describedhereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the features and advantages of thepresent invention, reference is now made to the detailed description ofthe invention along with the accompanying figures in which correspondingnumerals in the different figures refer to corresponding parts and inwhich:

FIG. 1 is a side elevational view with partial cross-section of oneembodiment of an automatic truck unloader positioning product within atrailer of a truck;

FIG. 2A is a top plan view of the automatic truck unloader illustratedin FIG. 1;

FIG. 2B is a side elevation view of the automatic truck unloaderillustrated in FIG. 1;

FIG. 2C is a second side elevation view of the automatic truck unloaderillustrated in FIG. 1;

FIG. 2D is a rear elevation view of the automatic truck unloaderillustrated in FIG. 1;

FIG. 2E is a front elevation view of the automatic truck unloaderillustrated in FIG. 1;

FIG. 2F is a front perspective view of the automatic truck unloaderillustrated in FIG. 1;

FIG. 2G is a rear perspective view of the automatic truck unloaderillustrated in FIG. 1;

FIG. 3A is a perspective view of a portion of the automatic truck loaderof FIG. 1 and in particular a detailed view of one embodiment of amobile base;

FIG. 3B is a second perspective view of the mobile base illustrated inFIG. 3A;

FIG. 4A is a front perspective view of one embodiment of an endeffector, which forms a portion of the automatic truck unloader;

FIG. 4B is a front elevation view of the end effector in FIG. 4A;

FIG. 4C is a side elevation view of the end effector in FIG. 4A;

FIG. 4D is a rear perspective of the end effector in FIG. 4A;

FIG. 4E is a cross-section view of the end effector along line 4E-4E ofFIG. 4C;

FIG. 5A is a side elevation view of one embodiment of an end effectorgripping a box in a first gripping position;

FIG. 5B is a side elevation view of the end effector in FIG. 5A grippinga box in a second gripping position;

FIG. 5C is a side elevation view of the end effector in FIG. 5A grippinga box in third gripping position;

FIGS. 6A through 6D are schematic diagrams of one operational embodimentof the automatic truck unloader of FIG. 1 unpacking boxes in the trailerof the truck;

FIGS. 7A through 7D are top plan views of an operational embodimentcorresponding to the operation shown in FIGS. 6A through 6D;

FIG. 8 is a schematic block diagram of one embodiment of the automaticcase loader;

FIG. 9 is a schematic block diagram of one embodiment of the automaticcase loader in additional detail;

FIG. 10 is a schematic diagram of one embodiment of a robot controllerwhich forms a portion of the automatic case loader;

FIG. 11 is a schematic diagram of one embodiment of a distancemeasurement subassembly which forms a component of the automatic caseloader; and

FIG. 12 is a schematic diagram of another embodiment of a distancemeasurement subassembly which forms a component of the automatic tireloader.

DETAILED DESCRIPTION OF THE INVENTION

While the making and using of various embodiments of the presentinvention are discussed in detail below, it should be appreciated thatthe present invention provides many applicable inventive concepts, whichcan be embodied in a wide variety of specific contexts. The specificembodiments discussed herein are merely illustrative of specific ways tomake and use the invention, and do not delimit the scope of the presentinvention.

Referring initially to FIG. 1, therein is depicted an automatic truckunloader that is schematically illustrated and generally designated 10and may be referred to as the automatic truck unloader. This automatictruck unloader 10 is utilized in systems and methods for automated truckunloading and packing of trailers, containers and the like. A tractortrailer 12 having an operator cab 14 is towing a trailer 16 having afront wall 18, two side walls 20A, 20B (best seen in FIGS. 6A through6D, for example), a floor 22, a ceiling 24, and a rear access opening 26accessible due to an open door. A bumper 28 of the trailer 16 is backedup to a loading bay of loading dock 32 such that the bumper 28 touches abumper 34 of the loading bay 30. A dock plate 36 bridges the gap betweenthe floor 22 and a deck 38 of the loading dock 32.

As will be described in further detail hereinbelow, under thesupervision of distance measurement subassembly or subassemblies thatare components of the automatic truck unloader 10, the automatic truckunloader 10 maneuvers and drives automatically into the trailer 16 to aposition as proximate as possible to the front wall 18. It should beappreciated that although an operator is not depicted as operating theautomatic truck unloader 10, an operator may be at location 40, anoperator platform, although unnecessary. The automatic truck unloader 10operates independently of an operator and an operator is only necessaryfor certain types of troubleshooting, maintenance, and the like. Atelescoping conveyor unit 42 is connected to the automatic truckunloader 10. A stream of product 46, in the form standard cases or boxes46A-46H, which may be of any dimension, is being supplied by theautomatic truck unloader upon removal thereof, as shown by arrow 48. Inparticular, the automatic truck unloader 10 has already unloaded boces46A through 46E, and others, for example, at the intersection of theproduct 46 proximate the front wall 18 and the floor 22. As shown, theautomatic truck unloader 10 is unloading box 46 f, which will befollowed by boxes 46 g, 46 h and other boxes 46. The automatic truckunloader 10 alternates between unloading the product 46 and drivingforward to create more opportunities to grip the product 46 between thefront wall 18 and the automatic truck unloader 10 until the trailer 16is at least partially unloaded of product 46.

FIG. 2A through FIG. 2G and FIG. 3A through FIG. 3B depict the automatictruck unloader 10 in further detail. A mobile base 50 supports a drivesubassembly 52, a conveyance subassembly 54, an industrial robot 56, apositioning subassembly 58, a safety subsystem 60, and a controlsubassembly 62, which interconnects the drive subassembly 52, conveyancesubassembly 54, industrial robot 56, positioning subassembly 58, andsafety subsystem 60. The mobile base 50 includes a front end 64 and arear end as well as sides 68, 70, a surface 72, and an undercarriage 74.

The drive subassembly 52 is coupled to the undercarriage 74 of themobile base 50 to provide mobility. As will be discussed in furtherdetail hereinbelow, drive wheel assemblies 78, 80, are disposed on theundercarriage 74 proximate to the sides 70, 68 respectively. A universalwheel assembly 82 is disposed on the undercarriage 74 more proximate tothe rear end 66 and centered between the sides 68, 70, respectively. Incombination, wheel assemblies 78, 80, 82 provide forward and reversedrive and steering. Retractable stabilization assemblies 84, 86 are alsodisposed on the undercarriage 74 proximate to the intersection of theend 64 and side 68, the intersection of end 66 and the side 70,respectively. As alluded to, in a forward or reverse drive and steeringoperation, such as moving into or out of the trailer 16, drive wheelassemblies 78, 80 and the universal wheel assembly 82 are actuated andin contact with the deck 38 of the loading dock 32 while the retractablestabilization assemblies 84, are withdrawn from contact with the deck 38in a position close to the undercarriage 74. On the other hand, when theautomatic truck unloader 10 is conducting a product loading or unloadingoperation, such as during the use of the industrial robot 56, theretractable stabilization assemblies 84, 86 are positioned in contactwith the deck 38 to anchor the automatic truck unloader 10. It should beappreciated that although the automatic truck unloader 10 is beingdescribed relative to unloading and unpacking, the automatic truckunloader 10 may also be used to load and pack product, including boxesand cases, into a trailer.

The conveyance subassembly 54 is disposed on the surface 72 of themobile base 50 to provide a powered transportation path 88 operable formeasuring, separating, carrying, and stacking, as required by theapplication and job assignment of the automatic truck unloader 10, boxesfrom the rear end 66 to the front end 64 proximate to the industrialrobot 56. As shown, the powered transportation path 88 includes apowered roller conveyor 90 having roller elements 92 which deliver theboxes 46 to a landing platform 94 where manipulation by the industrialrobot 56 is initiated. It should be appreciated that although only asingle powered roller conveyor 90 is display, the powered transportationpath 88 may include any combination and type of conveyors, elevators,stackers, and bypasses and the particular combination of componentsselected for the powered transportation path 84 will depend upon theparticular boxes or other product and application of the automatic truckunloader 10.

The conveyance subassembly 54 as well as the telescoping conveyor unit42 may also each be equipped with a series of end stop photo eyes toadjust the rate of automatic flow of product through the telescopingconveyor unit 42 and the conveyance subassembly 54. Such animplementation provides a steady and continuous flow of product,maintains proper box or product separation, and prevents unnecessarygaps between the product and product backups and jams.

A telescoping conveyor interface 104 couples the roller conveyor 90 ofthe conveyance subassembly 54 to the telescoping conveyor unit 42 andthe rest of a pick belt system which may be at the warehouse associatedwith the loading dock 32. Auto-follow circuitry associated with thetelescoping interface 104 of the telescoping conveyor unit and theconveyance subassembly 54 may utilize fiber optic sensors at the lastboom of the telescoping conveyor unit 42 detect reflective tape at theedge of the conveyance subassembly to cause the telescoping conveyorunit 42 to extend and retract to maintain the proper position withrespect to the automatic truck unloader 10. In another embodiment, thetelescoping conveyor unit 42 may be passive and the automatic truckunloader 10 may provide the force to extend or retract the telescopingconveyor unit 42.

The industrial robot 56 is disposed at the front end 64 and adapted toprovide selective articulated movement of an end effector 130 betweenthe landing platform 94 of the powered transportation path 88 and areachable space 132 such that the industrial robot 56 is operable toplace the product 46 in the reachable space 132. The end effector 130includes a gripper arm 134 adapted for manipulating product withcooperating and complementary grapplers 136A, 136B. It should beappreciated that any type of end effector 130 may be employed theindustrial robot and the choice of end effector 130 will depend upon theproduct 46 and specific automatic truck unloader 10 application. By wayof example, the gripper arm 134 with grapplers 136A, 138B is preferredfor unloading and unpacking boxes 46A-46H. It should be understood,however, that the product 46 may be any type of good such as other casedor non-cased objects requiring loading.

In one implementation, the industrial robot 56 includes seven segments130, 138, 140, 142, 144, 146, 148 joined by six joints 150, 152, 154,156, 158, 160 to furnish selective articulated movement having sixdegrees of freedom. More particularly, the referenced reachable space132, as best seen in FIGS. 2F and 2G, is defined by the movement of theindustrial robot 56 which provides rotation about six axes includingrotary movement of the entire industrial robot 56 about a primaryvertical axis; rotary movement of segment 146 having a tower structureabout horizontal axis to provide extension and retraction of the segment144 having a boom arm; rotary movement of the boom arm about thehorizontal axis to provide raising and lowering of the boom arm; andselective rotary movement about three wrist axes.

The positioning subassembly 58 is dispersed throughout the mobile base50. A distance measurement subassembly 170 disposed at the front end 64of the mobile base 50 measures distance and determines the presence ofobjects within a detection space 172 which is located in front of thefront end 64. In one embodiment, the detection space 172 and thereachable space 132 at least partially overlap. The distance measurementsubassembly 170 assists the automatic truck unloader 10 with forward andreverse movement and the repositioning of the automatic case loader 10to create additional empty reachable space 132 for the placement of theproduct 46. Further, the distance measurement subassembly 170 assistswith the coordination and operation of the industrial robot 56. Distanceand measurement information gathered by the distance measurementsubassembly 170 is provided to the control subassembly 62.

As will be discussed in further detail hereinbelow, the distancemeasurement subassembly 170 may be a laser range finding apparatusoperating on a time-of-flight measurement basis or principle or a camerasystem operating on an adaptive depth principle. It should beappreciated, however, that other types of distance measurements arewithin the teachings of the present invention. By way of example, andnot by way of limitation, the distance measurement subassembly mayinclude a laser range finding apparatuses, cameras, ultrasonicmeasurement apparatuses, inclinometers, and combinations thereof.Similar to distance measurement subassembly 170, distance measurementsubassemblies 174, 176 are respectively disposed at the sides 68, 70.The distance measurement subassemblies 174, 176 each may include in oneembodiment, detection spaces (not illustrated) to provide measurementand distance information to the control subassembly 62 during traversemovement operations of the automatic truck unloader 10.

The safety subsystem 60 is distributed and mounted to the mobile base50. The safety subsystem 60 may include a light tower which provides aquick indication of the current status of the automatic truck unloader10 to an operator and a wireless operator alert system 182 whichcontacts pagers or cellular devices of individuals through a wirelessnetwork. Also a cage and railing may be included around the operatorplatform 40 to provide additional safety to the operator. Emergencybuttons may be located throughout the automatic truck unloader 10 toprovide for instant and immediate power down. Front safety scanners 188and rear safety scanners 190 may be positioned at the front end 64 andthe rear end 64 to protect the automatic truck unloader 10, people, andproduct during a collision with an obstacle. Additionally, the frontsafety bumpers 188 and the rear safety bumpers 190 may include detectorsthat detect the presence of an object and cause an automatic power downduring a collision. Side safety scanners, although not illustrated, mayalso be utilized. It should be appreciated that other safety features,such as safety bumpers, may be integrated into the automatic truckunloader 10.

The control subassembly 62, which is also distributed and mounted to themobile base 50, may include control station having a user interfacedisposed at the side 70 near the operator platform 76. As discussed, thedrive subassembly 52, the conveyance subassembly 54, the industrialrobot 56, the positioning subassembly 58, and the safety subassembly 60are interconnected and in communication with the control subassembly 62via a network of concealed and sheathed cables and wires. With thisarrangement, the control subassembly 62 may coordinate the manual andautomatic operation of the automatic truck unloader 10. Further, avisual detection subsystem 162 is associated with the end effector suchthat the visual detection subsystem 162 captures an image of a productspace for processing by the control subassembly, as will be discussedfurther hereinbelow.

A main frame 200 is constructed of welded steel tubing includes tubularsections 202, 204, 206, and 208 which provide a rectangular framework.The tubular sections 202-208 are supported by tubular sections 208, 210,214, 216, 218, and 220, which augment and further support therectangular framework. All mounting plates, such as mounting plates 222,224 and bolt holes necessary to hold the various components attached tothe mobile base are included in the main frame 200. The large plates222, 224 hold, for example, the control station and the user interfacein position while providing counter weight for the automatic truckunloader 10 as well as balance with respect to the industrial robot 56disposed proximate to the mounting plates 222, 224. Additional counterweight may be supplied by tractor weights mounted proximate to the rearend 66, which also serve to add additional support and integrity to themain frame 200.

Drive wheel assemblies 78, 80 include a pair of front drive wheels 252,250 disposed proximate to the front end 64 and, more particularly,proximate the intersection of tubular sections 208, 214 and tubularsections 204, 214, respectively. Respective AC motors 254, 256 withdouble reduction gearboxes 258, 260 supply power thereto. The AC motor254 with double reduction gearbox 258 is disposed adjacent to thetubular section 214 and the front drive wheel 250. Similarly, the ACmotor 256 with double reduction gearbox 260 is disposed adjacent to thetubular section 214 and the front drive wheel 252. The universal wheelassembly 82 includes a rear steering wheel 284 mounted to a frame 286disposed proximate to the rear end 66.

With reference to the operation of the drive subassembly 52 inconjunction with the mobile base 50, the drive wheel assemblies 78, 80and universal wheel assembly 82 provide mobility along the length of theautomatic truck unloader 10. The AC motors 254, 256 with the respectivedouble reduction gearboxes 258, 260 drive the front drive wheels 250,252. In particular, each front drive wheel 250, 252 is independentlydriven to provide the ability to turn and to provide a pivoting drivemode. The universal wheel assembly 82 provides a rear steering wheel 284to provide enhanced steering capability for the automatic truck unloader10. In addition to providing forward and reverse capability, the oneembodiment, the drive subassembly 52 may furnish a traverse drive systemproviding the capability to move the entire automatic truck unloader 10perpendicular to a trailer or fixed object at the loading dock 32.

Referring now to FIGS. 4A through 4E, wherein a gripper arm 134 of theend effector 130 having grippers 136A, 136B is depicted. Moreparticularly, the gripper arm 134 includes a main frame 280 having asupport frame 281 for attachment to the industrial robot 56. A movingframe half 282 is selectively pivotally coupled to the main frame 280 bya joint 284 to provide a range of motion between approximately aparallel presentation between the main frame 280 and the moving frame282 and approximately an orthogonal presentation between the main frame280 and the moving frame 282. The joint 284 comprises hinge pairs 286,288 secured by hinge pins 290, 292. Self aligning ball bearings 294, 296are respectively located at each of the hinge pairs 286, 288 to providefor improved engagement between the main frame 280, moving frame half282 and the surface of a product, such as a case or box. A shoulderfastener 298 and ball joint end rod 300, which also couple the mainframe 280 to the moving frame half 282, actuate the selective pivotalmovement of the moving frame half 282 relative to the main frame 280.

Multiple suction cups 302 are associated with a face 303 of the mainframe 280 and, similarly, multiple suction cups 304 are associated witha face 305 of the moving frame half 282. Bulk head fittings 306 securethe multiple suction cups 304 to the moving frame half 282. Within themain frame 280, a paddle cylinder 308, straight fitting 310, and anelbow fitting 312 secure vacuum manifolds 314, 316 within the main frame280 in pneumatic communication with the suction cups 302, 304. Vacuumsensors 318, 320 are mounted in the main frame 280 proximate to thesuction cups 302. A visual detection subsystem 162 is housed in the mainframe and includes a camera assembly 322, lighting assembly 324, and acamera mount 326.

Referring now to FIGS. 4A through 5C, in an unloading operation, thevacuum sensors 318, 320 senses for the presence of a box 46. In responseto detecting an object, such as a box 46 having a top T, the vacuumsensors 318, 320 actuate the vacuum manifolds 314, 316 to generate avacuum force to grip the object via the suction cups 302, 304. As shownin FIGS. 5A through 5C, the industrial robot 56 and gripper arm 134 maygrip a box 46 in any one of three positions depending on the demands ofthe unloading or unpacking operation. A bottom-front grip (FIG. 5A), atop-front grip (FIG. 5B) or a top grip (FIG. 5C) may be used.

FIGS. 6A through 6D depict one operational embodiment of the automatictruck unloader 10 unloading or unpacking boxes 46A-46S in the trailer ofthe truck. Referring now to FIG. 6A, boxes 46A-46G are positioned in anempty trailer of the truck to be unloaded by the automatic truckunloader 10. More specifically, the distance measurement subassembly 170continuously determines the position of the automatic truck unloader 10within the trailer and the presence of objects, including boxes 46, isknown. When beginning a removal operation, the automatic truck unloader10 identifies a product space, e.g., space of boxes 46A through 46S,including a product skyline 330 and chooses an active quadrant 332 tobegin unstacking operations. The active quadrant 332 is a subspace ofthe product space. Additionally, using the visual detection subsystem162, a protruding object is identified and removed. In FIG. 6A, theremoval is initiated by removing box 46B.

With reference to FIG. 6B, the unloading and unpacking continues in theactive quadrant 332 at newly defined skyline 332 with the removal of box46A, then 46C. As the product space diminishes, the active quadrant isreadjusted and within each new skyline, the boxes are removed based onprotrusion, which in one embodiment may be height. With reference toFIG. 6C, this methodology continues with the skyline 330 and activity inquadrant 332. In this active quadrant 332, box 46J, then 46K, then 46Lare removed. The sequential removal of boxes continues until the trailerof the truck is almost empty as shown in FIG. 6D, with boxes 46P through46S remaining to be removed.

FIGS. 7A through 7D, wherein one embodiment of an automated truckunloading system and methodology are illustrated for the automatic truckunloader 10 of the present invention. Initially, as shown in FIG. 7A,the trailer 16 is positioned under the power of the tractor trailer 12at the loading bay 30 of the loading dock 32 approximate to the deck 38where the automatic truck unloader 10 is working. The trailer 16 isreversed, set-up, and activated in a usual manner. The dock plate 36 isdeployed from the loading bay 30 into the trailer 16 to provide abridge. Thereafter, the trailer 16 is inspected for significant damagethat may interfere with the automated loading operations of theautomatic truck unloader 10. Additional inspection may include ensuringthe trailer is reasonably centered within the loading bay 30 andensuring the deck 38 is clear of any obstructions. At this time, by wayof further safety measures, a kingpin lockout may be installed toprevent a driver from accidentally pulling out the trailer 16 from theloading bay 30 when the automatic truck unloader 10 is operating withinthe trailer 16. The kingpin lockout or similar safety precautionsprotect both the operator and the equipment and ensures that the wheelsof the trailer 16 are chocked and will not roll during the use of theautomatic truck unloader 10.

Continuing to refer to FIG. 7A, once the trailer 16 is positioned in theloading bay 30, the automatic truck unloader 10 is moved in front of therear access opening 26 of the trailer 16. The automatic truck unloader10 utilizes either a manual or automatic reverse mode to assist theoperator (whether on the automatic truck unloader 10 or at a remotelocation) in backing the automatic truck unloader 10 up to thetelescoping conveyer unit 42 in a position that is square thereto. Theconveyance subassembly 54 of the automatic truck unloader 10 is thencoupled to the telescoping conveyor unit 42. At this time, as the dockplate 36 has been positioned from the deck 38 to the trailer 16, theautomatic truck unloader may be advanced into the interior of thetrailer 16 proximate the row of boxes 344 j, which forms one of the rowsof boxes 344 a through 344 j with 344 a being proximate to the front ofthe trailer 16 and 344 j at the rear.

With reference to FIG. 7B, the automatic truck unloader 10 has advancedforward into the trailer 16 and, in one embodiment, the positioningsubassembly 58 and, in particular, the distance measurement subassembly170 continuously determines the position of the automatic truck unloader10 within the trailer 16. More specifically, several measurements aremade. The position and angle of the automatic truck unloader 10 aremeasured with respect to the sidewalls 20A, 20B and an interior widthdefined thereby. Also, measurements are made with respect to a near wallwithin the trailer 16 and the floor 22. The near wall being the closerof the front wall 18 of the trailer or the edge formed by product 46,e.g. cases, positioned within the trailer 16. The angle relative to thefloor 22 proximate to the automatic truck unloader 10 is measured as theautomatic truck unloader traverses the dock plate 36 and moves into thetrailer 16. In one embodiment, following successful traversal, the anglerelative to the floor 22 may be assumed to be constant.

In this way, as the automatic truck unloader 10 moves, the position ofthe automatic truck unloader 10 relative to objects in its environment,including boxes, is known and the automatic truck unloader 10 may adjustoperation appropriately. Adjustments in operation may include, but arenot limited to, the operation of the industrial robot 56, the operationof the conveyance subassembly 54, and the actuation of the drivesubassembly 52. The position of the sidewalls 20A, 20B and the near wallis utilized to determine the position of the automatic truck unloader 10along the length of the trailer 16, the position across the width of thetrailer 16, and the automatic case loader's angle relative to thesidewalls 20A, 20B or yaw. The measurements also determine the positionof the automatic truck unloader 10 relative to the floor 22 of thetrailer 16. To assist the automatic truck unloader 10 in determiningposition within the trailer 16, in one implementation, the automatictruck unloader 10 is programmed with the dimensions of the trailer 16.

Additionally in one embodiment, the automatic truck unloader 10 isprogrammed with the reachable space 132 of the industrial robot 56. Asillustrated, once the automatic truck unloader is positioned proximateto the row of boxes 344 j such that the removal of boxes 46 within thetrailer 16 may begin and the boxes 46 are within the reachable space 132of the industrial robot 56, the automatic truck unloader 10 stopsadvancing. Continuing to refer to FIG. 7B, boxes 46 are conveyed to thetelescoping conveyor unit 42 form the conveyance subassembly 54 and thisstream of boxes 46 is presented by the industrial robot 56 during theunloading/unpacking operation. With selective articulated movementthrough the reachable space 132, the industrial robot 56 removes theboxes 46 from the trailer and sequentially selects the box to be removedbased on how far particular boxes in an active quadrant protrude.

As depicted in FIG. 7C, the automatic truck unloader 10 has completedunloading multiple horizontal rows 344B-344J of boxes 46. During theunloading operation, the unloading of the boxes 46 by the industrialrobot 56 is temporarily interrupted in response to the distancemeasurement subassembly 170 detecting the absence of the boxes 46 withinthe reachable space 132. Further, with this information being availableto the control subassembly 62, a signal may be sent to the conveyancesubassembly 54 to slow down or temporarily halt the powered transport ofthe product 46.

As a result of the completion of the removal of boxes in a row, such asrows 344B-344J, the automatic truck unloader 10 periodically drivesforward and repositions to refresh the reachable space 132 such that theautomatic truck unloader 10 is positioned proximate to the wall ofplaced boxes 46, e.g., the product space, in order that the removal ofadditional boxes 46 against the wall of placed boxes 46 is within thereachable space 132 of the industrial robot 56. During the repositioningof the automatic truck unloader 10, the telescoping conveyor unitappropriately advances, while maintaining contact with the conveyancesubassembly 54, to accommodate the new position of the automatic caseloader/unloader 10.

Referring to FIG. 7D, the iterative unstacking operations andrepositioning of the automatic truck unloader 10 described in FIGS. 7Athrough 7C continues and the trailer 16 is empty. With respect to FIG.8D, the trailer 16 is completely empty with boxes 46, including rows344A-344J being removed, and the automatic truck unloader 10 is reversedto a position entirely on the deck 38. Thereafter, the trailer 16emptied of boxes may leave the loading dock 32 and a fresh full trailermay then be positioned at the loading bay 30 and unloaded in the mannerdescribed herein.

FIG. 8 depicts one embodiment of the automatic truck unloader 10 inwhich the automatic truck unloader 10 is schematically depicted toinclude a computer-based architecture including a processor 350 coupledto a bus 352 having transmitter/receiver circuitry 354, outputs 356,inputs 358, memory 360, and storage 362 interconnected therewith. In oneembodiment, the control assembly 192 includes the memory 360, which isaccessible to the processor 350. The memory 360 includesprocessor-executable instructions that, when executed cause theprocessor 350 to execute instructions for unpacking or unloading boxes46 or other objects. By way of example and not by way of limitation, theinstructions may be directed specifying a search operation to identify aproduct skyline within a product space. Then, a search operation may bespecified to identify an active quadrant within the product space and asearch operation may be specified to identify a protruding productwithin the active quadrant at the product skyline. Upon theidentification of the protruding product, a removal operation may bespecified to unload the product corresponding to the protruding productand instructions calculated for removing the product corresponding tothe protruding product. These instructions may iteratively continue.

FIG. 9 depicts one embodiment of the automatic truck unloader 10 and thecontrol signals associated therewith, which may be deployed across thecomputer architecture shown in FIG. 9, for example. The illustratedcomponents coordinate the various functions and operations of theautomatic truck unloader 10. The user interface 194, operationalenvironment database 370, programmable logic controller 372, robotcontroller 374, and distance measurement subassemblies 170, 174, 176 areinterconnected. The drive subassembly 52, conveyance subassembly 54, asrepresented by control 376 for conveyors/elevators, and safetycontroller 378 are connected to the programmable logic controller 372.Finally, the industrial robot 56 is connected to the robot controller374. In one implementation, the user interface 194, operationalenvironment database 370, and programmable logic controller 372 are partof the control subassembly 62 and the robot controller 374 forms aportion of the industrial robot 56. The safety controller 358 isincluded in the safety subsystem 60 and provides operation to theaforementioned components of this subsystem.

The user interface 194 provides user control and interaction with theautomatic truck unloader 10. The user interface 194 may utilize icons inconjunction with labels and/or text to provide navigation and a fullrepresentation of the information and actions available to the operator.In addition to loading operations, user interactions may be related tomaintenance, repair and other routine actions which keep the automatictruck unloader 10 in working order or prevent trouble from arising.

The operational data environment database 370 includes data about thereachable space 132 of the industrial robot 56, stacking methodologydata, product information as well as information about the standardsizes of trailers. The product information may be stored in theoperational data environment database 350, gathered by the conveyancesubassembly 54 as previously discussed, or gained by a combinationthereof. By having the standard sizes of trailers pre-loaded, operatortime is saved from having to enter this data and performance of theautomatic truck unloader 10 is improved with this additionalinformation. By way of example, Tables I & II present exemplary examplesof type of trailer data that the automatic truck unloader 10 may utilizein determining position and product placement.

TABLE I TRAILER DIMENSIONS Inside Inside Door Trailer Inside HeightHeight Opening Type Length Width Center Front Width 28′ 27′3″ 100″  109″107″ 93″  (8.5 m)  (8.3 m) (2.5 m) (2.8 m) (2.7 m) (2.4 m) High Cube 45′44′1½″ 93″ 109″ 106″ 87″ (13.7 m) (13.4 m) (2.4 m) (2.8 m) (2.7 m)   (2m) Wedge 48′ 47′3″ 99″ 110½″ 108½″ 93″ (14.6 m) (14.4 m) (2.5 m) (2.8 m)(2.8 m) (2.4 m) Wedge

TABLE II TRAILER DIMENSIONS CONTINUED Door Rear Trailer Opening FloorCubic Overall Overall Type Height Height Capacity Width Height 28′ 104″47½″ 2029 cft 102″ 13′6″  (8.5 m) (2.6 m) (1.2 m) (57.5 cm) (2.6 m) (4.1m) High Cube 45′ 105½″ 50″ 3083 cft  96″ 13′6″ (13.7 m) (2.7 m) (1.3 m) (7.3 cm) (2.4 m) (4.1 m) Wedge 48′ 105″ 48½″ 3566 cft 102″ 13′6″ (14.6m) (2.7 m) (1.2 m)  (101 cm) (2.6 m) (4.1 m) Wedge

The programmable logic controller 372 coordinates overall operation andswitches between various modes of operation including manual andautomatic. The programmable logic controller 372 also provides for thehigh-level calculation and coordination required during automaticoperation for items such as the current unload quadrant unloading andsteering angel calculations during automatic navigation.

The robot controller 374 controls the motions of the industrial robot 56through built in inputs and outputs wired through the industrial robot56 and the end effector 130. It should be appreciated that although aparticular architecture is presented for the control of the automaticcase loader, other architectures are within the teachings of the presentinvention. By way of example, any combination of hardware, software, andfirmware may be employed. By way of further example, the distribution ofcontrol may differ from that presented herein.

In one operation embodiment, the programmable logic controller 372accesses the dimensions of the trailer from the operational environmentdatabase 372. The operator 40 has indicated through the user interface194 which type of trailer has arrived at the docking bay 30.Alternatively, the distance measurement subassembly 170 is operable todetect this information. The distance measurement subassemblies 170,174, 176 relay distance and position data to the programmable logiccontroller 352 which uses this information to send control signals tothe robot controller 374, the drive subassembly 52, the controller 372,and the safety controller 378. Additionally, the programmable logiccontroller 372 receives control signals, which are inputs into thebehavior process, from each of these components. Constant updates andstatus information are provided to the operator by the programmablelogic controller 352 through the user interface 194.

FIG. 10 depicts one embodiment of the robot controller 372 which forms aportion of the automatic truck unloader 10. The essence of the robotcontrol 372 is a robot system or control program 380, which controls theindustrial robot 56. The control program 380 can be operated by theoperator 40 by means of an operating service 362 in communication withthe user interface 194 and receives input data (as well as provideinstructions, as appropriate) from the operational environmentaldatabase 370, programmable logic controller 372, and distancemeasurement subassembly 170 by means of a driver 384. It should beappreciated, that the independence of the robot controller 374 may vary.In one implementation, the robot controller 374 may be under the controlof the programmable logic controller 374. In another implementation, asillustrated, the robot controller 374 is more autonomous and may includefeatures such as direct connection to the user interface 194.

According to one embodiment, between the driver 384 and the controlprogram 380 is provided an independent data processing layer in the formof a frame program 386, which controls the robot movements, and a unit388 for automated or event-controlled strategy or behavioral selectionon the basis of the states and signals which occur. User applicationprograms, event-controlled strategy selections and sensor programs inthe frame program 386 can be programmed by the operator 40 and directedby a robot program 390, which monitors the balance and implementation ofmanual and automatic control of the industrial robot 56.

FIG. 11 depicts one embodiment of a distance measurement subassembly,i.e., a laser measurement sensor 400. A staging circuit 402 causes apulsed laser 404 to transmit light pulses while causing the rotation ofa light deflecting device 406 via controller 408 which may be equippedwith a rotational means and a motor. The angular position of the lightdeflecting device 406 is continuously communicated to the stagingcircuit 402 by the controller 408. Light pulses are transmitted into thedetection space 172 via the transmitter lens and the mirrors associatedwith the light deflection device 406. More particularly, when the rotarymirror of the light deflection device 406 is driven by the controller408 to execute a continuous rotary movement, the staging circuit 402causes the pulsed laser 404 to transmit a light pulse. The light pulseis transmitted into the detection space 172 and is reflected from anobject, so that finely a received pulse enters into a photo receivingarrangement 410. In this manner the light reaches the photo receiverarrangement 410 after a light transit time t of 2d/c, where d is thespace in the object from the apparatus and c is the speed of light.

The time t between the transmission and reception of the light pulse ismeasured with the aid of a comparator 412 having time interval computerfunctionality. On transmitting the light pulse, a counter functionwithin the comparator 412 is triggered and is stopped again by the photoreceiver arrangement 410 via the comparator 412 on receiving the lightpulse from the detection space 172.

A corresponding electrical signal is formed and applied via comparator412 to a laser scanner controller 414, signal to noise processor 416 anda detector 418, which analyzes the signal for objects and in the instantexample determines that an object is present. The task of the signal tonoise processor 416 is to control the detection threshold independenceon the received noise level. This control ensures a constant false alarmrate with varying illumination situations and object reflection factors.The signal to noise processor 416 makes available this information tothe laser scanner controller 414. The laser scanner controller 414performs peak value calculations based on the data from the comparator412, the signal to noise processor 416, and the detector 418.

As the laser scanner controller 414 knows the instantaneous angularposition of the light pulses by way of communication with the stagingcircuit 402, the laser scanner controller 414 determines the location ofthe object and other navigational properties. The laser scannercontroller 414 is adapted to forward this information to othercomponents.

FIG. 12 is a schematic diagram of a distance measurement subassembly170, which is depicted as a three dimensional (3-D) measurement system450, which includes an illumination assembly 452 and an image capturesubassembly 454 that together utilize a laser and/or infrared-basedcamera application employing an adaptive depth principle. Theillumination assembly 452 includes a light source 456 and a transparency458, which may include a positive image on a transparent support with avarious sorts of fixed, uncorrelated patterns of spots, for example.

The light source 456 transilluminates transparency 458 with opticalradiation so as to project an image of the spot pattern that iscontained by the transparency onto object 46A, which is depicted as aproduct, but may also include various environmental information aboutthe storage container. The image capture assembly 454 captures an imageof the pattern that is projected by illumination assembly 452 onto theproduct 46A. The image capture assembly 454 may include objective optics464, which focus the image onto an image sensor 460. Typically, theimage sensor 460 includes a rectilinear array of detector elements 462,such as a CCD or CMOS-based image sensor array.

As should be appreciated, although the illumination assembly and imagecapture assembly are shown as held in a fixed spatial relation, variousother positioning techniques may be employed to create a dynamicrelationship therebetween. Moreover, the three-dimensional x, y, z axismay be employed in this regard. To generate a 3D map of object orproduct 46A, including the environment, a processor, which mayincorporated into processor 350 or associated therewith, compares thegroup of spots in each area of the captured image to the reference imagein order to find the most closely-matching group of spots in thereference image. The relative shift between the matching groups of spotsin the image gives the appropriate x, y or Z-direction shift of the areaof the captured image relative to the reference image. The shift in thespot pattern may be measured using image correlation or other imagematching computation methods that are known in the art. By way ofexample, the operation principle may include an infrared adaptive depthprinciple utilizing laser or infrared cameras.

While this invention has been described with reference to illustrativeembodiments, this description is not intended to be construed in alimiting sense. Various modifications and combinations of theillustrative embodiments as well as other embodiments of the invention,will be apparent to persons skilled in the art upon reference to thedescription. It is, therefore, intended that the appended claimsencompass any such modifications or embodiments.

What is claimed is:
 1. An automatic truck unloader forunloading/unpacking product from a trailer, the automatic truck unloadercomprising: a base structure having first and second ends; an industrialrobot disposed at the second end of the base structure; a distancemeasurement subassembly disposed at the second end, the distancemeasurement subassembly configured to determine presence of objectswithin a detection space; a control subassembly mounted to the basestructure, the control subassembly being in communication with theindustrial robot, and the distance measurement subassembly, the controlsubassembly coordinating the selective articulated movement of theindustrial robot and the activation of the drive subassembly based uponthe distance measurement subassembly detecting objects within thedetection space; and the control assembly including a memory accessibleto a processor, the memory including processor-executable instructionsthat, when executed cause the processor to: specify a search operationto identify a product skyline within a product space, specify a searchoperation to identify an active quadrant within the product space,specify a search operation to identify a protruding product within theactive quadrant at the product skyline, and specify a removal operationto unload the product corresponding to the protruding product.
 2. Theautomatic truck unloader as recited in claim 1, wherein the industrialrobot further comprises selective articulated movement of an endeffector between the powered transportation path and a reachable spacesuch that the industrial robot is operable to handle the product in thereachable space, the end effector further including a suction cup-basedgripper arm.
 3. The automatic truck unloader as recited in claim 2,wherein the end effector further comprises a suction cup-based gripperarm adapted for manipulating a box with cooperating grapplers that gripthe box in a gripping position selected from the group consisting ofparallel to the box and perpendicular to the box.
 4. The automatic truckunloader as recited in claim 2, wherein the end effector furthercomprises: a main frame having a support frame for attachment to theindustrial robot; a moving frame half selectively pivotally coupled tothe main frame by a joint to provide a range of motion betweenapproximately a parallel presentation between the main frame and themoving frame and approximately an orthogonal presentation between themain frame and the moving frame; a first plurality of suction cupsassociated with a face of the main frame; a second plurality of suctioncups associated with a face of the main frame; a vacuum manifold housedwithin the main frame in pneumatic communication with the first andsecond pluralities of suction cups; a vacuum sensor mounted in the mainframe proximate to the first plurality of suction cups, the vacuumsensor, in response to detecting an object, being configured to actuatethe vacuum manifold and generate a vacuum force to grip the object; anda visual detection subsystem housed in the main frame, the visualdetection subsystem being configured to capture an image of the productspace for processing by the control subassembly.
 5. The automatic truckunloader as recited in claim 1, further comprising a visual detectionsubsystem associated with the end effector, the visual detectionsubsystem being configured to capture an image of the product space forprocessing by the control subassembly.
 6. The automatic truck unloaderas recited in claim 5, wherein the visual detection subsystem furthercomprises a camera and lighting assembly for digitally imaging theproduct space.
 7. The automatic truck unloader as recited in claim 1,wherein the product space is a subspace of the detection space.
 8. Theautomatic truck unloader as recited in claim 1, wherein the activequadrant is a subspace of the product space.
 9. The automatic truckunloader as recited in claim 1, further comprising a drive subassemblycoupled to the base structure, the drive subassembly including aplurality of wheels having a pair of front drive wheels disposedproximate to the second end, the pair of front drive wheels beingpowered by respective AC motors with double reduction gearboxes.
 10. Theautomatic truck unloader as recited in claim 1, wherein the basestructure further comprises a mobile base structure.
 11. The automatictruck unloader as recited in claim 1, a conveyance subassembly disposedon the mobile base structure, the conveyance subassembly including apowered transportation path operable for transporting product betweenthe first end and the second end.
 12. The automatic truck unloader asrecited in claim 11, wherein the conveyance subassembly furthercomprises a conveyor having a telescoping conveyor interface forcoupling the automatic case loader to a telescoping conveyor unit. 13.The automatic truck unloader as recited in claim 1, wherein the distancemeasurement subassembly comprises a three-dimensional measurement systemoperating on an adaptive depth measurement principle.
 14. The automatictruck unloader as recited in claim 1, wherein the distance measurementsubassembly comprises a device selected from the group consisting oflaser range finding apparatuses, cameras, ultrasonic measurementapparatuses, inclinometers, and combinations thereof.
 15. The automatictruck unloader as recited in claim 1, wherein the dimensions of thetrailer are programmed into the control subassembly.
 16. An automatictruck unloader for unloading/unpacking product from a trailer, theautomatic truck unloader comprising: a base structure having first andsecond ends; an industrial robot disposed at the second end of the basestructure, the industrial robot providing selective articulated movementof an end effector between the powered transportation path and areachable space such that the industrial robot is operable to handle theproduct in the reachable space; the end effector including a suctioncup-based gripper arm adapted for manipulating a box with cooperatinggrapplers that grip the box in a gripping position selected from thegroup consisting of parallel to the box and perpendicular to the box;means for determining presence of objects within a detection space,wherein the detection space and the reachable space at least partiallyoverlap; a control subassembly mounted to the base structure, thecontrol subassembly being in communication with the industrial robot,and the distance measurement subassembly, the control subassemblycoordinating the selective articulated movement of the industrial robotand the activation of the drive subassembly based upon the distancemeasurement subassembly detecting objects within the detection space,and dimensions of the trailer provided to the control subassembly; andthe control assembly including a memory accessible to a processor, thememory including processor-executable instructions that, when executedcause the processor to: specify a search operation to identify a productskyline within a product space, specify a search operation to identifyan active quadrant within the product space, and specify a searchoperation to identify a protruding product within the active quadrant atthe product skyline.
 17. The automatic truck unloader as recited inclaim 16, further comprising a visual detection subsystem associatedwith the end effector, the visual detection subsystem being configuredto capture an image of the product space for processing by the controlsubassembly.
 18. An automatic truck unloader for unloading/unpackingproduct from a trailer, the automatic truck unloader comprising: a basestructure having first and second ends; an industrial robot disposed atthe second end of the base structure, the industrial robot providingselective articulated movement of an end effector between the poweredtransportation path and a reachable space such that the industrial robotis operable to handle the product in the reachable space; the endeffector including a main frame having a support frame for attachment tothe industrial robot; a moving frame half selectively pivotally coupledto the main frame by a joint to provide a range of motion betweenapproximately a parallel presentation between the main frame and themoving frame and approximately an orthogonal presentation between themain frame and the moving frame; a first plurality of suction cupsassociated with a face of the main frame; a second plurality of suctioncups associated with a face of the main frame; a vacuum manifold housedwithin the main frame in pneumatic communication with the first andsecond pluralities of suction cups; a vacuum sensor mounted in the mainframe proximate to the first plurality of suction cups, the vacuumsensor, in response to detecting an object, being configured to actuatethe vacuum manifold and generate a vacuum force to grip the object; avisual detection subsystem housed in the main frame, the visualdetection subsystem being configured to capture an image of the productspace for processing by a control subassembly; a distance measurementsubassembly disposed at the second end, the distance measurementsubassembly configured to determine presence of objects within adetection space, wherein the detection space and the reachable space atleast partially overlap; the control subassembly mounted to the basestructure, the control subassembly being in communication with theindustrial robot, and the distance measurement subassembly, the controlsubassembly coordinating the selective articulated movement of theindustrial robot and the activation of the drive subassembly based uponthe distance measurement subassembly detecting objects within thedetection space, and dimensions of the trailer provided to the controlsubassembly; and the control assembly including a memory accessible to aprocessor, the memory including processor-executable instructions that,when executed cause the processor to: specify a search operation toidentify a product skyline within a product space, specify a searchoperation to identify an active quadrant within the product space, andspecify a search operation to identify a protruding product within theactive quadrant at the product skyline.
 19. The automatic truck unloaderas recited in claim 18, further comprising a visual detection subsystemassociated with the end effector, the visual detection subsystem beingconfigured to capture an image of the product space for processing bythe control subassembly.